Parallel-Wire Coil Layout for High-Current Compact Winding
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Solution Overview
Problem
Conventional coil devices face challenges in handling increased electric current due to the difficulty in bending thick wires, complicating wire joint operations and enlarging the device size, especially in vertical-type coil devices where terminal electrodes are joined by laser welding on the side surface of the flange portion.
Innovation Solution
A coil device design featuring two wires wound around a magnetic core with terminal electrodes arranged to allow separate current flow, using insulated terminal electrodes and diagonal wire-joint portions to facilitate easy connection and reduce the need for thick wires, thereby enabling high electric current capacity without enlarging the device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a thick wire is used to handle increased electric current, then the electric current capacity is improved, but the wire joint operation becomes difficult and the device size increases
Solution Approach 1:
The patent divides the current path into multiple parallel paths by using multiple wires (first wire and second wire) wound around the magnetic core. Each wire carries a portion of the total current, allowing the device to handle high current without requiring any single wire to be excessively thick, thus maintaining ease of wire joint operation.
2Power
If a thick wire is used to handle increased electric current, then the electric current capacity is improved, but the device size increases
Solution Approach 1:
The patent divides the current path into multiple parallel paths by using multiple wires (first wire and second wire) wound around the magnetic core. Each wire carries a portion of the total current, allowing the device to handle high current without requiring any single wire to be excessively thick, thus maintaining ease of wire joint operation.
3Productivity
If multiple wire-joint portions are connected close together by laser welding, then the manufacturing efficiency is improved, but the thermal influence adversely affects connection reliability
Solution Approach 1:
The patent spatially segments the wire-joint portions on the flange portion, arranging them at different locations. This segmentation allows laser welding to be performed on each wire-joint portion separately with minimal thermal interference between adjacent joints, maintaining connection reliability while enabling efficient manufacturing.
4Volume of moving object
If wire-joint portions are arranged close together, then the flange portion thickness can be reduced, but the thermal influence of connection operation adversely affects other wire-joint portions
Solution Approach 1:
The patent arranges wire-joint portions at specific locations on the flange portion where they can be closely spaced to minimize overall device size, while the local geometry and positioning ensure that thermal influence from laser welding at one joint does not adversely affect other joints. This maintains both compactness and connection reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design allows for a compact coil device capable of handling high electric current with improved joint reliability and reduced thermal influence on connections, while maintaining a low profile and minimizing thermal stress on the magnetic core, even in severe temperature environments.
Implementation Method 1
a first terminal electrode and a second terminal electrode attached to the flange portion so as to be insulated from each other
Implementation Method 2
the terminal electrode and the wire can be joined by laser welding on the side surface of the flange portion
Data Source
AI summary
A coil device includes a magnetic core, a first wire and a second wire, and a first terminal electrode and a second terminal electrode. The magnetic core includes a winding core portion and a flange portion. A first end of the first wire is connected to a first wire-joint portion of the first terminal electrode. A first end of the second wire is connected to a second wire-joint portion of the first terminal electrode. A second end of the first wire is connected to a first wire joint portion of the second terminal electrode. A second end of the second wire is connected to a second wire-joint portion of the second terminal electrode. The first wire-joint portion and the second wire-joint portion are arranged away from each other. The first wire-joint portion and the second wire joint portion are arranged away from each other.